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Round Ductwork Installation Tips

Round metal ductwork is versatile, long-lasting and easy to work with. Learn the best methods for cutting and installing it from a master tin bender.

By the DIY experts of The Family Handyman Magazine

Working with round ducts

Whether you’re adding new heat runs in a basement or changing the layout of an existing HVAC system, you’ll probably be working with round metal duct pipe. We invited Bob Schmahl to give us a few pointers. Bob’s been a tin bender for more than 40 years. He insists he still doesn’t know everything about ductwork, but we weren’t convinced. These tips should help make your next job run that much smoother.

Install dampers at the registers

Don't peel off old tape

Bob's not a fan of flexible duct

Assemble the pipe like a zipper

A hole cutter works great in tight spots

Overlap butt joints with draw band connectors

Caulk the take-offs

Leave backing on the tape

Make two marks for cutting

Use support brackets and three screws

Move one ring at a time

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Required Tools for this Project

Have the necessary tools for this DIY project lined up before you start—you’ll save time and frustration.

    • Cordless drill
    • Caulk gun
    • Safety glasses
    • Utility knife
    • Tin snips

In addition you will need a hole cutter, a right angle drill or right angle attachment and leather gloves.

Required Materials for this Project

Avoid last-minute shopping trips by having all your materials ready ahead of time. Here's a list.

    • Damper
    • Foil tape
    • Draw band connector
    • Silicone caulk
    • 1-in. galv. zip screws for metal
    • Adjustable elbows
    • Ductwork

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Round Ductwork Installation Tips

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